Visor

ABSTRACT

A visor assembly including a pivoted cover for a vanity mirror which includes camming surfaces on the pivot socket for urging the cover between open and closed positions. In one embodiment, the visor is selectively illuminated by the operation of a cover controlled switch. In another embodiment, the mirror and cover assembly is snap fitted within the visor.

RELATED APPLICATIONS

This is a continuation of co-pending prior application Ser. No. 211,993,filed, June 27, 1988 by VandenBerge et al and entitled VISOR, abandoned,which is a continuation application of prior application Ser. No.912,798, filed Sept. 26, 1986, by VandenBerge et al and entitled VISORand now U.S. Pat. No. 4,760,503.

BACKGROUND OF THE INVENTION

The present invention pertains to a visor and particularly to a visorhaving a vanity mirror.

Illuminated vanity mirror visors have become a popular accessory on manyvehicles and standard equipment on several vehicle models. Such visorsprovide the normal sun blocking functions and in addition provide avanity mirror which can be illuminated for use under low ambient lightconditions. The mirror in such visor is selectively covered by aprotective cover to conceal the mirror when not in use. This visorconstruction is disclosed in U.S. Pat. No. 4,227,241, issued Oct. 7,1980, and entitled VISOR ASSEMBLY. In such visor construction, the coveris spring biased to selective open and closed positions so that thecover will remain closed under the force of the spring or remain in asnapped-open position. A coil spring coupled to the visor mirror frameand to an arm on the cover pivot is employed to provide this desirablecover control.

Other visor controls have also been proposed such as a spring coupledbetween the visor frame and directly to the cover as, for example,disclosed in U.S. Pat. No. 4,491,899, issued Jan. 1, 1985, and entitledVISOR COVER ASSEMBLY. Also, a visor cover pivot rod and mirror framesocket have included camming means for controlling the visor cover. Suchstructure is disclosed, for example, in U.S. Pat. No. 4,213,169, issuedJuly 15, 1980, and entitled COVERED VISOR MIRROR. Other covered vanitymirror visors have employed L-shaped leaf springs extending between aseparate housing for a mirror frame and a cover mounted to the housingto cooperate with tabs on the cover for urging and holding the coverbetween closed and open positions.

Some of the covered vanity mirror visors also include lights for themirror to facilitate its use in low ambient light conditions. It isdesirable for safety and convenience to actuate the lights by theactuation of the cover, and a variety of switch arrangements have beenproposed such as those set forth in U.S. Pat. No. 4,000,404, issued Dec.28, 1976, and entitled VISOR ILLUMINATED MIRROR; and U.S. Pat. No.4,075,468, issued Feb. 21, 1978, and entitled VISOR AND MIRROR ASSEMBLY.In addition, push-button switches mounted to the mirror frame andactuated upon opening and closing of the cover have been provided ashave knife switches with one element of the knife switch mounted to thecover and the remaining element of the knife switch mounted to themirror housing.

SUMMARY OF THE PRESENT INVENTION

According to one aspect of the present invention a covered vanity mirrorvisor is provided with improved control means for holding the cover ineither a fully opened or fully closed position. Visors embodying thisinvention include a leaf spring mounted to the mirror frame of the visorfor engaging camming means integral with the cover and pivot means ofthe cover for urging the cover toward open or closed positions. In apreferred embodiment of the invention, the leaf spring is generallyT-shaped including means for captively holding the spring in apredetermined position for engagement by the camming means associatedwith the cover. In the preferred embodiment also, the cover cam meansare integrally formed with a pivot socket of the visor cover.

According to another aspect of the present invention, the vanity mirrorvisor includes means for providing illumination for the mirrorassociated therewith which includes an electrical switch having astationary contact and a movable contact which is engaged by fingermeans on the cover such that as the cover is moved between an open andclosed position, the movable switch contact is positively closed oropened respectively by the finger means to assure the switch is actuatedwhen the cover is open for providing illumination for the illuminatedvanity mirror and opened when the cover is closed to assure theilluminating means is extinguished. In a preferred embodiment of theinvention, the movable switch contact comprises a resilient arm, and thecover cam means comprise a pair of spaced fingers spanning oppositesides of the arm to urge the arm in opposite directions for opening andclosing the switch.

According to yet a further aspect of the invention, the vanity mirrorassembly of the present invention comprises a package which isinsertable and snap fitted in a recess formed in a visor body and whichcan be readily assembled from a minimum of parts thereby reducing theoverall cost of the system. These and other features, objects andadvantages of the present invention will become apparent upon readingthe following description thereof together with reference to theaccompanying drawings in which:

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front elevational view partly broken away and partly inphantom form of a visor embodying the present invention;

FIG. 2 is a front elevational view of the visor shown in FIG. 1 shownwith the mirror cover moved to an open position and with the mirrorpartly broken away and one lens removed to show the positioning of theelectrical circuit elements associated with the illuminated vanitymirror visor;

FIG. 3 is a partly exploded view of the illuminated vanity mirrorassembly which is incorporated in the visor shown in the FIGS. 1 and 2;

FIG. 4 is an enlarged fragmentary perspective view of the circled areashown in FIG. 3 and shown with a portion of the mirror frame showing therelationship of the cover operational elements;

FIG. 5 is an enlarged fragmentary cross-sectional view taken alongsection lines V--V of FIG. 1;

FIG. 6 is a right side elevational view of the structure shown in FIG.5; and

FIG. 7 is a fragmentary enlarged cross-sectional view taken alongsection lines VII--VII of FIG. 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring initially to FIG. 1, there is shown a visor 10 mounted to theroof 12 of a vehicle such as an automobile by a conventional elbowbracket pivot assembly 14 which includes a horizontal axle 16 extendingwithin the body of the visor near the upper edge 11 thereof. Visor 10pivots on axle 16 by means of a torque device 18 which can be of thetype described in U.S. Pat. No. 4,500,131, issued Feb. 19, 1985, andentitled VISOR CONTROL. This permits the visor 10 to be moved from araised stored position against the vehicle headliner when not in use ora lowered use position as illustrated in FIGS. 1 and 2. The left edge ofthe visor remote from pivot connection 14 includes a stub axle 19 whichfits within a suitable clip mounted to the vehicle for supporting theopposite end of the visor.

Visor 10 includes a body made of a polymeric core 20 typically molded intwo halves hinged together and which includes a generally rectangularrecess 22 centrally located in one side thereof for receiving anilluminated vanity mirror assembly 30. The visor core 20 is covered by asuitable upholstery material 24 to conform the visor's appearance tothat of the interior of the vehicle in which it is installed. Recess 22of the visor core 20 includes a floor 23 (FIG. 2) onto which the circuitelements of assembly 30 can be installed as described below. Theconstruction of the illuminated vanity mirror assembly 30 can best beunderstood by reference to FIG. 3 now described.

Assembly 30 includes a generally rectangular mirror frame assembly 40defined by a rectangular flange 45 having a central generallyrectangular opening 42 for receiving and holding a rectangular mirror 44which is inserted from the rear and held in place along the edges ofopening 42 by heat deformed tabs. Adjacent and spaced on each side ofaperture 42 are lens receiving apertures 41 and 43 for receiving leftand right side lenses 51 and 53 respectively, which snap fit withinapertures 41 and 43 and which are keyed thereto by means of keying tabsand slots at their edges. Lenses 51 and 53 are designed to directillumination from lamps 61 and 63 positioned behind the lenses withinapertures 41 and 43 outwardly and centrally toward the face of the userof the mirror 44.

Mirror frame 40 includes downwardly depending peripheral walls 46 withthe front wall as seen in FIG. 3 including spaced looking tabs 47 whichcooperate with slots 25 (FIG. 7) formed in the edge wall 24 of recess 22for snap fitting mirror frame 40 into the visor body recess attachingthe frame to the molded core 20. The polymeric molded mirror frame 40also integrally includes a pair of pivot axles 48 and 49 spaced alongthe top edge 50 of the frame generally in alignment with lens apertures41 and 43. Axles 48 and 49 are circular and are integrally formed by aninjection molding of suitable material such as polyvinyl chloride orA.B.S. and which includes the forming of adjacent rectangular clearanceapertures 48' and 49' allowing socket means associated with a mirrorcover 70 and shown in detail in FIG. 4 to partially circumscribe each ofthe axles 48 and 49 and extend through the adjacent apertures 48' and49'.

The upper edge 50 of mirror frame 40 includes an upwardly openingU-shaped structure including the wall 46, integral floor 54 and anupwardly extending vertical end wall 52 to provide a pocket forreceiving the upper edge of cover 70 and stiffening of the frame memberalong the top edge adjacent pivot axles 48 and 49. The integral floorfurther includes cross members 55 and 56 extending below and across eachof the apertures 41 and 43 respectively. Each cross member is supportedat its outer end by a downwardly extending peripheral side wall 46 andat its inner, opposite end by a downwardly projecting inner wall 57adjacent one of apertures 41 and 43. The cross members 55 and 56 eachinclude an upwardly projecting indexing tab 58 and 59 for positioningand holding one end of a T-shaped leaf spring 80 mounted to the frame40.

As seen in FIGS. 3 and 4, the assembly includes a pair of the T-shapedsprings 80 with each spring including a central leg 82 having anaperture 84 near its end which extends over the indexing projection 58or 59. Leg 82 integrally extends from the top member 86 of each of thesprings 80 which is curved in a convex fashion as viewed in FIG. 3 withupwardly turned ends 87 and 88 which rest against the floor 54 of theU-shaped portion of frame 40. Leg 82 extends through an access opening26 in the upper peripheral wall 46 as best seen in the left side of FIG.3, such that the indexing tabs 58 or 59 captively holds each of thesprings 80 in position with respect to frame 40. In their installedposition, the intersection of legs 82 and 86 is approximately alignedunderneath the pivot axles 48 and 49 to engage the integral cam andsocket means on cover 70 as described below in connection with FIG. 4.

In FIG. 4, the upper surface area of frame 40 surrounding aperture 49'is not illustrated nor is the pivot axle 49 for the sake of clarity inshowing the camming means and pivot socket associated with cover 70 inrelation to the spring 80. Cover 70 includes along its inner top edge apair of spaced open semicylindrical resilient pivot sockets 90 which arealigned to fit over pivot axles 48 and 49. The right side socket 90 isillustrated in FIG. 4 and includes a pair of arms 92 and 94 with arm 92integrally formed and attached to the inner surface of the polymericcover 70 near the top edge 72 thereof. .Arms 94 and 92 are joined bycurved section 93 defining a semicircular socket with arm 94sufficiently resilient so that the open sockets so formed can be snapfitted over axles 48 and 49 thereby attaching the cover to the mirrorframe 40.

Integrally formed and extending on the outer surface of each of thegenerally C-shaped sockets so formed is a vertically extending flange100 with outer edge surfaces defining camming means having a firstcamming surface 102 which engages leg 82 of spring 80 as shown in FIG. 4when the cover is in the open position for holding the cover in the openposition by the effective force provided by the flattened otherwiseconvexly curved spring 80 exerting a force upwardly against surface 102which is slightly offset from the axis R of rotation of the cover withrespect to the mirror frame for holding the cover in an open position.Cam means includes a second camming surface 104 extending at an angle ofapproximately 110° from surface 102 and joined thereto by a roundedcorner 105 permitting the cover to easily move from the open to theclosed position. When the cover is manually rotated to the closedposition, surface 104 now engages leg 82 of spring 80 tending to urgethe cover toward the closed position by a force now extending on theupper portion of axis R of rotation of the cover. Thus, the spring means80 and integral socket and cam 90 provided for each of the pivot axles48 and 49 exert a force which tends to snap open the cover when movedtoward the open position and snap and hold closed the cover when movedtoward the closed position.

The electrical system for actuating lamps 61 and 63 is best seen withreference to FIGS. 2 and 3. The positive supply conductor 110 extendsthrough a central opening in the hollow pivot rod assembly 14 and 16 andterminates in a connector 112 coupled to a suitable supply conductorfrom the vehicle's electrical system. Conductor 110 extends into thehollow core 20 of visor 10 and is held to the floor 23 of the visor coreby suitable resilient sockets 114. Conductor 110 extends to a firstmovable contact 120 of the cover actuated switch 125 which comprises acombination of the movable contact 120 and a fixed contact 130. Movablecontact 120 as best seen in FIG. 3, is generally U-shaped having one leg123 including a tab 12 for receiving a snap-on terminal at the end ofconductor 110 for coupling conductor 110 to the contact. The center leg122 of the generally U-shaped contact 120 is held between two fingers130 and 132 (FIGS. 5 and 6) extending downwardly from the top edge 72 ofcover 70 for controlling the movable contact and specifically therounded contact end 124 thereof in relation to the contact portion 134of fixed contact 130. Contact 130 is heat staked to the floor 23 of core20 as seen in FIG. 2 with a conductor 132 extending therefrom to oneside of each of a pair of bulb sockets 161 and 163. The remaining commonterminal of sockets 161 and 163 are coupled by a conductor 140 to aground contact 142 which as seen in FIG. 2, is mounted to engage andcontact the end of the metallic pivot rod 16 which is coupled to thevehicle ground through the metallic pivot assembly 14. Movable switchcontact 120 is held in position against floor 23 of core 20 by a firstintegrally molded polymeric lug 126 and a second lug 128 at the bend ofthe U-shaped bendable contact between leg 122 and the left downwardlydepending leg 123 as best seen in FIG. 2. Tab 126 extends over the topof the contact 120 to hold it against floor 23 but with sufficientclearance to move freely in a direction toward and way from fixedcontact 130.

With cover 70 in an open position as illustrated in FIG. 2, cam member130 associated with cover 72 as shown in FIG. 5, moves in a clockwisedirection as shown in FIG. 5 by arrow A to urge against the upper andouter surface of leg 122 of switch 120 pushing it downwardly towardfixed contact 130 thus making electrical contact as illustrated in FIG.2. The electrical current supplied by conductor 110 is thereby appliedto conductor 132 and to sockets 161 and 163 which are grounded byconductor 140. This illuminates bulbs 61 and 63 fitted within thesockets. As the cover is closed, however, finger 130 disengages contact122 and finger 132 engages the lower inside surface of contact arm 122as seen in FIG. 5, as the cover is moved in a now counterclockwisedirection opposite arrow A in the figure thereby lifting the contact end124 away from contact 134 of the fixed contact 130 of switch 125. Thisthen opens the electrical circuit to lamps 61 and 63 therebyextinguishing them. By cradling the movable contact section 122 betweentwo spaced fingers 130 and 132 therefor, the cover 70 provides positivecontrol both for the closing and opening of the electrical switch 125which assures reliable operation of the switch, the contacts of whichare each made from a bendable conductive material such as a brass alloy.

During manufacture, the electrical wiring including contacts 120 and 130and sockets 161 and 163 with bulbs are inserted onto the receivingreceptacles in the integrally formed core floor 23. Next, the cover andmirror package is assembled by first inserting the mirror withinaperture 42 and springs 80 within their respective apertures and inalignment over pins 58 an 59 followed by the lenses 51 and 53. The cover70 is then snap fitted over pivot arms 48 and 49 and moved to a closedposition. The package, including frame 40 and cover 70, is then pushedwithin the recess 22 of the visor with camming fingers 130 and 132automatically aligned on opposite sides of leg 122 of switch contact125. The unit is then depressed inwardly into the visor until thelocking tabs 47 on the side walls of the downwardly depending flangessnap into correspondingly shaped apertures 25 in the side wall 24 of therecess 22 as seen in FIG. 7, thereby holding the illuminated vanitymirror package in position and completing the assembly.

It will become apparent to those skilled in the art that variousmodifications to the preferred embodiment of the invention can be madewithout departing from the spirit or scope thereof as defined by theappended claims.

The embodiments of the invention in which an exclusive property ofprivilege is claimed are defined as follows;
 1. A visor for a vehicleincluding a visor body having a recess formed in one side for receivinga covered vanity mirror assembly, said covered vanity mirror assemblycomprising:a mirror frame including a mirror receiving central openingand a peripheral flange extending around said opening and extending in aplane generally parallel to the plane of said visor body, said frameincluding one of a pair of spaced pivot axles and sockets extendingadjacent one edge of said flange; a cover including the other of a pairof spaced pivot axles and sockets to permit said cover to be pivotallymounted to said frame to pivot between open and closed positions toselectively cover said mirror, at least one of said pair of pivot axlesand sockets including a pair of camming surfaces offset from the axis ofrotation of said cover; and spring bias means captively mounted to saidflange for engaging said camming surfaces for selectively urging andholding said cover in either an open or closed position, and whereinsaid bias means is supported by said frame at spaced-apart locations,wherein said bias means is a T-shaped leaf spring having a central legand a cross member, wherein said cross member is slidably mounted tosaid frame, and said flange includes means for holding an end of saidcentral leg remote from said cross member in a substantially fixedposition.
 2. The apparatus as defined in claim 1 wherein said centralleg includes an aperture near an end remote from said cross member andwherein said holding means comprises a projection extending into saidaperture.
 3. The apparatus as defined in claim 2 wherein each of saidsocket means are formed on said cover and includes camming surfaces andsaid bias means comprises a pair of T-shaped leaf springs for engagingsaid camming surfaces of said socket means.
 4. An accessory for avehicle including a body having a recess formed in one side forreceiving a covered vanity mirror assembly, said covered vanity mirrorassembly comprising:a mirror frame including a mirror receiving centralopening and a peripheral flange extending around said opening andextending in a plane generally parallel to the plane of said visor body,said frame including one of a pair of spaced pivot axle and socketsextending adjacent one edge of said flange; a cover including the otherof a pair of spaced pivot axles and sockets to permit said cover to bepivotally mounted to said frame to pivot between open and closedpositions to selectively cover said mirror, at least one of said pair ofpivot axles and sockets including a pair of camming surfaces offset fromthe axis of rotation of said cover; and spring bias means captivelymounted to said flange for engaging said camming surfaces forselectively urging and holding said cover in either an open or closedposition, and wherein said bias means is supported by said frame atspaced-apart locations, and wherein said bias means is a T-shaped leafspring having a central leg and a cross member wherein said cross memberis slidably mounted to said frame, and said flange includes means forholding an end of said central leg remote from said cross member in asubstantially fixed position.
 5. The apparatus as defined in claim 4wherein said central leg includes an aperture near an end remote fromsaid cross member and wherein said holding means comprises a projectionextending into said aperture.
 6. The apparatus as defined in claim 5wherein each of said socket means are formed on said cover and includescamming surfaces and said bias means comprises a pair of T-shaped leafsprings for engaging said camming surfaces of said socket means.
 7. Aspring-loaded hinge assembly for interconnecting an accessory door withan accessory housing structure for a vehicle, said hinge assemblycomprising:pivot means pivotally interconnecting the door with thehousing structure for rotational movement of the door relative to thehousing structure about an axis; a cam member protruding in a generallylateral direction from one of the door and the housing structure;resilient biasing means disposed on the other of the housing structureand the door, said resilient biasing means being slidably andresiliently deflectably engageable by said cam for exerting a resilientbiasing force on said cam in a generally lateral direction generallytoward said axis; and support means interconnected with the housingstructure for supporting said resilient biasing means in a directiongenerally opposite the direction of said engagement of said resilientbiasing means by said cam, said support means including seat portionsfor slidably supporting said resilient biasing means at one of twospaced-apart locations thereon and anchoring said resilient biasingmeans at the other of two spaced-apart locations thereon.
 8. Aspring-loaded hinge assembly for interconnecting a cover door to avanity mirror assembly for a vehicle visor, said hinge assemblycomprising:pivot means pivotally interconnecting the door with thevanity mirror assembly for rotational movement of the door relative tothe mirror assembly about an axis; a cam member protruding in agenerally lateral direction from the door; resilient biasing meansdisposed on the mirror assembly, said resilient biasing means beingslidably and resiliently deflectably engageable by said cam for exertinga resilient biasing force on said cam in a generally lateral directiongenerally toward said axis; and support means interconnected with themirror assembly for supporting said resilient biasing means in adirection generally opposite the direction of said engagement of saidresilient biasing means by said cam, said support means including seatportions for slidably supporting said resilient biasing means at one oftwo spaced-apart locations thereon and anchoring said resilient biasingmeans at the other of said spaced apart locations.
 9. A visor for avehicle including a visor body having a recess formed in one side forreceiving a covered vanity mirror assembly, said covered vanity mirrorassembly comprising:a mirror frame including a mirror receiving centralopening, said frame including one of a pair of spaced pivot axles andsockets extending adjacent one edge of said frame; a cover including theother of a pair of spaced pivot axles and sockets to permit said coverto be pivotally mounted to said frame to pivot between open and closedpositions to selectively cover said mirror, at least of said pair ofpivot axles and sockets including a pair of camming surfaces offset fromthe axis of rotation of said cover; and a leaf spring captively mountedto said frame for engaging said camming surfaces for selectively urgingand holding said cover in either an open or closed position, whereinsaid leaf spring is supported by said frame at spaced-apart locationssuch that one end of said leaf spring is slidably supported by saidframe and an opposite end of said leaf spring is anchored at a fixedposition.